Nissan ZD30 & TD27Ti Engines Service & Repair Manual

ENGINE MECHANICAL SECTION EM CONTENTS ZD PRECAUTIONS ...............................................................3 Parts Requiring Angular Tightening .............................3 Liquid Gasket Application Procedure ..........................3 PREPARATION ................................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................8 NVH Troubleshooting Chart - Engine Noise ...............9 MEASUREMENT OF COMPRESSION PRESSURE ....10 INTERCOOLER ............................................................. 11 Removal and Installation ........................................... 11 INTAKE MANIFOLD ......................................................12 Removal and Installation ...........................................12 Inspection...................................................................13 CATALYST AND TURBOCHARGER ............................14 Removal and Installation ...........................................14 Inspection...................................................................15 EXHAUST MANIFOLD ..................................................18 Removal and Installation ...........................................18 Inspection...................................................................19 ROCKER COVER ..........................................................20 Removal and Installation ...........................................20 OIL PAN & OIL STRAINER...........................................22 Removal and Installation ...........................................22 VACUUM PUMP ............................................................24 Removal and Installation ...........................................24 TIMING CHAIN ..............................................................26 Removal and Installation ...........................................26 Removal .....................................................................26 Installation ..................................................................28 CAMSHAFT ...................................................................30 Removal and Installation ...........................................30 Removal .....................................................................30 Inspection...................................................................31 Installation ..................................................................33 VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS.............................................................35 Inspection...................................................................35 Adjustments ...............................................................36 TIMING GEAR ...............................................................38 Removal and Installation ...........................................38 Removal .....................................................................39 Inspection...................................................................41 Installation ..................................................................46 OIL SEAL REPLACEMENT ..........................................50 CYLINDER HEAD..........................................................52 Removal and Installation ...........................................52 Removal .....................................................................52 Inspection...................................................................53 Installation ..................................................................54 Disassembly...............................................................57 Inspection...................................................................58 Assembly ...................................................................61 ENGINE REMOVAL .......................................................63 Precautions ................................................................63 Removal .....................................................................63 Installation ..................................................................65 Inspection...................................................................65 CYLINDER BLOCK .......................................................66 Selection Procedure for Selective Part Combination ...............................................................67 Disassembly...............................................................67 Inspection...................................................................71 Assembly ...................................................................80 SERVICE DATA AND SPECIFICATIONS (SDS) ..........84 General Specifications ...............................................84 Compression Pressure ..............................................84 Cylinder Head ............................................................84 Valve ..........................................................................84 Valve Seat ..................................................................87 Camshaft and Camshaft Bearing ..............................89 Cylinder Block ............................................................90 Piston, Piston Ring and Piston Pin ...........................90

Connecting Rod .........................................................91 Crankshaft..................................................................92 Available Main Bearing ..............................................92 Available Connecting Rod Bearing............................93 Miscellaneous Components.......................................94 TD27Ti PRECAUTIONS .............................................................95 Parts Requiring Angular Tightening ...........................95 Liquid Gasket Application Procedure ........................95 PREPARATION ..............................................................96 Special Service Tools ................................................96 Commercial Service Tools .........................................99 ENGINE COMPONENTS - Outer Parts .....................100 ENGINE COMPONENTS - Internal Parts ..................102 COMPRESSION PRESSURE......................................103 Measurement of Compression Pressure .................103 CYLINDER HEAD........................................................104 Removal ...................................................................105 Disassembly.............................................................106 Inspection.................................................................107 Assembly ................................................................. 113 Installation ................................................................ 114 OIL SEAL REPLACEMENT ........................................ 117 TURBOCHARGER....................................................... 119 Removal and Installation ......................................... 119 Inspection................................................................. 119 ENGINE REMOVAL .....................................................123 ENGINE OVERHAUL ..................................................125 Disassembly.............................................................125 Inspection.................................................................127 Assembly .................................................................138 SERVICE DATA AND SPECIFICATIONS (SDS) ........143 General Specifications .............................................143 Inspection and Adjustment ......................................144 CONTENTS (Cont’d) EM-2

Parts Requiring Angular Tightening I Use an angle wrench for the final tightening of the cylinder head bolts. I Do not use a torque value for final tightening. I The torque value for these parts are for a preliminary step. I Ensure thread and seat surfaces are clean and coated with engine oil. Liquid Gasket Application Procedure 1. Use a scraper to remove old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. 2. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine Liquid Gasket or equivalent.) I Be sure liquid gasket diameter is as specified. 3. Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). 4. Assembly should be done within 5 minutes after coating. 5. Wait at least 30 minutes before refilling engine oil and engine coolant. SEM164F AEM080 PRECAUTIONS ZD EM-3

Special Service Tools Tool number Tool name Description ST0501S000 Engine stand assembly q 1 ST05011000 Engine stand q 2 ST05012000 Base NT042 Disassembling and assembling KV10106500 Engine stand shaft NT028 KV11106101 Engine sub-attachment NT819 KV10115600 Valve oil seal drift NT603 Installing valve oil seal Use side A. Side A a: 20 (0.79) dia. b: 13 (0.51) dia. c: 10.3 (0.406) dia. d: 8 (0.31) dia. e: 10.7 (0.421) f: 5 (0.20) Unit: mm (in) KV10107902 Valve oil seal puller q 1 KV10116100 Valve oil seal puller adapter NT605 Removing valve oil seal KV101056S0 Ring gear stopper q 1 KV10105630 Adapter q 2 KV10105610 Plate NT617 Preventing crankshaft from rotating a: 3 (0.12) b: 6.4 (0.252) c: 2.8 (0.110) d: 6.6 (0.260) e: 107 (4.21) f: 14 (0.55) g: 20 (0.79) h: 14 (0.55) dia. Unit: mm (in) PREPARATION ZD EM-4

Tool number Tool name Description KV101151S0 Lifter stopper set q 1 KV10115110 Camshaft pliers q 2 KV10115120 Lifter stopper NT041 Changing shims KV101092S0 Valve spring compressor q 1 KV10109210 Compressor q 2 KV10109220 Adapter NT718 Disassembling and assembling valve components ED19600620 Compression gauge adapter NT820 Checking compression pressure ST16610000 Pilot bushing puller NT045 Removing crankshaft pilot bushing KV10111100 Seal cutter NT046 Removing steel oil pan and rear timing chain case WS39930000 Tube presser NT052 Pressing the tube of liquid gasket KV10112100 Angle wrench NT014 Tightening bolts for bearing cap, cylinder head, etc. PREPARATION ZD Special Service Tools (Cont’d) EM-5

Tool number Tool name Description KV10109300 Pulley holder NT628 a: 68 mm (2.68 in) b: 8 mm (0.31 in) dia. KV111045S1 Balancer shaft bearing replacer set q 1 KV11104510 Replacer bar q 2 KV11104521 Guide plate q 3 KV11104530 Adapter (Front bearing) q 4 ST15243000 Drift NT258 Removing and installing balancer shaft bearing Commercial Service Tools Tool name Description Valve seat cutter set NT048 Finishing valve seat dimensions Piston ring compressor NT044 Installing piston assembly into cylinder bore Piston ring expander NT030 Removing and installing piston ring Standard Universal NT808 Removing and installing transmission mount PREPARATION ZD Special Service Tools (Cont’d) EM-6

Tool name Description Deep socket (12 mm) NT821 Removing and installing glow plugs PREPARATION ZD Commercial Service Tools (Cont’d) EM-7

SEM290G NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ZD EM-8

NVH Troubleshooting Chart — Engine Noise Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Location of noise Type of noise Operating condition of engine Source of noise Check item Reference page Before warm-up After warm-up When starting When idling When racing While driving Top of engine Rocker cover Cylinder head Ticking or clicking C A — A B — Tappet noise Valve clearance MA section (“Adjusting Intake & Exhaust Valve Clearance”, “ENGINE MAINTE- NANCE”) Rattle C A — A B C Camshaft bearing noise Camshaft bushing clearance Camshaft runout EM-31, 31 Crankshaft pulley Cylinder block (Side of engine) Oil pan Slap or knock — A — B B — Piston pin noise Piston and piston pin clearance Connecting rod bushing clearance EM-71, 73 Slap or rap A — — B B A Piston slap noise Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion EM-75, 72, 72, 73 Knock A B C B B B Connecting rod bearing noise Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end) EM-73, 77 Knock A B — A B C Main bearing noise Main bearing oil clearance Crankshaft runout EM-78, 76 Front of engine Timing gear cover Tapping or ticking A A — B B B Timing gear noise Timing gear backlash EM-41 Front of engine Squeaking or fizzing A B — B — C Other drive belts (Stick- ing or slip- ping) Drive belts deflection MA section (“Checking Drive Belts”, “ENGINE MAINTE- NANCE”) Creaking A B A B A B Other drive belts (Slip- ping) Idler pulley bearing operation Squall Creak A B — B A B Water pump bearing noise Water pump bearing operation LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”) A: Closely related B: Related C: Sometimes related —: Not related NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ZD EM-9

1. Warm up engine. 2. Turn ignition switch OFF. 3. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC section, “Fuel Pressure Release”. I Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and for error detection at the end of this operation. 4. Disconnect the negative battery terminal. 5. Remove the following parts. I Intercooler I Throttle body I Rocker cover 6. To prevent fuel from being injected during inspection, remove fuel injection pump fuse [ENG CONT A/T (15A)] from fuse box on the right side of engine compartment. 7. Remove glow plugs from all the cylinders. I Before removal, clean the surrounding area to prevent entry of any foreign materials into the engine. I Carefully remove glow plugs to prevent any damage or breakage. I Handle with care to avoid applying any shock to glow plugs. 8. Install adapter (SST) to installation holes of glow plugs and connect compression gauge for diesel engine. : 15 - 19 N⋅m (1.5 - 2.0 kg-m, 11 - 14 ft-lb) 9. Connect battery negative terminal. 10. Set the ignition switch to “START” and crank. When gauge pointer stabilizes, read compression pressure and engine rpm. Repeat the above steps for each cylinder. I Always use a fully-charged battery to obtain specified engine speed. Unit: kPa (bar, kg/cm 2 , psi)/rpm Standard Minimum Difference limit between cylinders 2,942 (29.42, 30.0, 427)/ 200 2,452 (24.52, 25.0, 356)/ 200 294 (2.94, 3.0, 43)/200 I When engine rpm is out of the specified range, check the spe- cific gravity of battery liquid. Measure again under corrected conditions. I If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves, valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower surfaces) and measure again. 11. Complete this operation as follows: a. Turn the ignition switch to “OFF”. b. Disconnect battery negative terminal. c. Replace glow plug oil seals and install glow plugs. d. Install fuel injection pump fuse [ENG CONT A/T (15A)]. e. Connect battery negative terminal. f. Using CONSULT-II make sure no error code is indicated for items of self-diagnosis. Refer to EC section, “Trouble Diagno- sis — Index”. YEM039 SEM334G MEASUREMENT OF COMPRESSION PRESSURE ZD EM-10

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Nissan ZD30 & TD27Ti Engines Service & Repair Manual

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